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PROCEDURE NO: C12-001/PSP/QAQC- 006

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Page 2 of 21 TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

1.0 PURPOSE ... 3 2.0 SCOPE ... 3 3.0 REFERENCES... 3 4.0 DEFINITIONS ... 3 5.0 PROCEDURES ... 4 5.1 Type of Weld / Item... 4

5.2 Equipment... 4 5.3 Equipment Calibration... 4 5.4 Consumables... 5 5.5 Surface Preparation... 5 5.6 Inspection Method... 5 5.7 Magnetization Technique... 6

5.8 Magnetic Flux Indicator... 6

5.9 Demagnetization... 6

5.10 Viewing Condition... 7

5.11 Interpretation and Evaluation... 7

5.12 Acceptance Criteria... 7 5.13 Qualification of Personnel... 7 5.14 Reports... 7 6.0 SPECIAL REQUIREMENT... 8 7.0 RECORD... 8 Detail I……… 9 ATTACHMENT. Attachment 1: Magnetic Particle Inspection Report ... 21

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Page 3 of 21 1.0 PURPOSE

This procedure describes the technique of magnetic particle examination on ferromagnetic materials.

2.0 SCOPE

This procedure covers for magnetic particle examination method to detect cracks and others discontinuities on surface and sub-surface of butt welds, fillet welds, back gouged area and parent materials of carbon steel material.

3.0 REFERENCES

The following codes and standards shall form part of the requirements of this procedure.

ASME Sect. V : Non – Destructive Examination Article 7 (2007 Edition). ASTM E709 : Standard Guide For Magnetic Particle Examination.(2001) AWS D1.1 : Structural Welding Code (2008)

4.0 DEFINITIONS

NDT : Non-destructive Testing.

PCN : Personnel Certification in Non-Destructive Testing. ASME : American Society of Mechanical Engineer.

ASTM : American Society for Testing and Materials.

CSWIP : Certification Scheme of Welding and Inspection Personnel. AWS : American Welding Society.

SNT-TC-1A : Personnel Qualification And Certification in Non Destructive Testing MT : Magnetic Testing

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Page 4 of 21 5.0 PROCEDURE

5.1 Types of Weld/Item

Butt Weld, Groove Weld and Fillet Weld of any ferromagnetic materials. 5.2 Equipment

5.2.1 Electro – Magnetic Yoke

Magnaflux Y-6 or Y1, Handy Magna MP-A2

A/C Current Magnetization (13Amp 240 V) or equivalent. 5.2.2 Permanent – Magnetic Yoke Magnaflux Y-5, Electro Spect

PM-6 or equivalent.

Any other equipment to be used shall meet requirement of section 5.3. 5.3 Equipment Calibration

The magnetizing force of a magnetic yoke shall be calibrated at least once a year or whenever it has been damage or repair.

5.3.1 Calibration Procedure

• Adjust the pole at maximum spacing i.e 150mm.

• Place the yoke on the calibrated dead weight block, 10lb (4.5kg) for AC Yoke and 40lb (18kg) for permanent magnet yoke. • Energize the AC Yoke or engage the permanent yoke and slowly

lift the dead weight block for 10 seconds.

• Observe the yoke shall be capable to lift the dead weights as specified by code and standard.

5.3.2 The requirement of Alternating Current Electromagnetic

The yoke shall have a lifting power of at least 10 Ib (4.5kg) at the maximum pole spacing i.e 150mm.

5.3.3 The requirement of Permanent Magnetic

The Yoke shall have a lifting power of at least 40Ib (18 kg) at the maximum pole spacing i.e 150mm.

5.3.4 Equipment performance check shall be carried out weekly.

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Page 5 of 21 5.4 Consumables

The chemicals used as detecting media shall be complied with ASMT E709, Standard Recommended Practice for MT. The following chemicals shall be used for testing and to be recorded(report as per attachment 1)

i) Magnaflux WCP-2 / Ely White Contrast Paint / Chemetall WCP -712 (or equivalent)

ii) Magnaflux 7-HF / Ely Black Magnetic Ink / Chemetall Supramor For Black ink (or equivalent)

5.5 Surface Preparation

5.5.1 Prior to Magnetic Particle examination, the surface to be examined and all adjacent areas within of least 25mm shall be dry and free from of all dirt, grease or etc.

5.5.2 Painted parts shall be tested only the paint from a thin, coherent coating, tightly adhering to the surface and not thicker than 50 micrometer.

5.5.3 Loose rust and loose scale shall be removed and cleaned. 5.6 Inspection Method

All inspections shall be conducted with the wet method where is applicable and alternate dry method shall be approved by client on case by case basis. Details method of inspection is referred to Detail I.

5.6.1 Wet Method

A uniform layer of thin coating of Magnaflux White Contrast medium shall be applied to the surface by spraying and then allowed to dry sufficiently. Spraying shall normally be done at 15-30cm distance. Contrast paint to be applied to a thickness not exceeding 20 microns. Then, apply the magnetization unit and during the process apply the Black Magnetic Ink suspension onto tested part. Simultaneously observation shall be done carefully to visualize any presence of crack or surface discontinuity. Wet method shall normally be performed to surfaces where temperature does not exceed 50 degree C. 5.6.2 Dry Method

Dry magnetic particle shall only be used when temperatures of test surface exceed 50 degree C and not more than 316

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Dry magnetic particles shall be applied in such a manner that a light uniform, dust-like coating settles upon the surface of the test part while the part is being magnetized.

The dry particles can be applied by powder blowers or hand powders applicator.

5.7 Magnetization Technique

5.7.1 For normal testing condition, at least two (2) separate examinations shall be performed on each test area. During the second examination, lines of magnetic flux shall be approximately perpendicular to those used in the first examination. All tests done shall be carefully attended to assure sufficient overlap of 100% coverage on tested areas.

5.7.2 The maximum pole spacing shall be 6 inches, in order to maintain sufficient test sensitivity. The distance of Yoke location for subsequent test should no more than 3 inches and shall have minimum of 10% lap.

5.8 Magnetic Flux Indicator

The sensitivity of the Magnetic Field shall normally be established by using the Magnetic Flux Indicator. It shall be placed perpendicularly to the direction of the Magnetic Field and to be demonstrated in at least three (3) lines of magnetic black ink shall appear on the Burmah Castrol Strip. The type of flux indicators shall be used either ASME Magnetic Field Indicator or Burmah Castrol.

5.9 Demagnetization

When residual magnetization in the part could interfere with subsequent processing or usage, the part be demagnetized any time after completion of the examination.

Demagnetization may be accomplished by subjecting the part to a reverse magnetic field direction. A-C yoke may

5.9.1 Used for local demagnetization by placing the pole on the part surface, moving them around the area, and slowly withdrawing the A-C Yoke while it is still energized.

5.9.2 Care should be exercised to ensure the part is entirely removed from the influence of the A-C yoke before the demagnetizing force is discontinued, otherwise the demagnetizer may have reverse effect of magnetizing the part.

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5.9.3 The effectiveness of the demagnetizing operate can be indicated by the use of appropriate magnetic field or field

strength meters. 5.10 View Conditioning

The area under inspection shall be illuminated by daylight or artificial light from either a normal tungsten filament lamp or a fluorescent tube. The level of illumination shall not less than 1000 lux or 100 foot candles as to enable a proper evaluation to be made of the indications revealed.

5.11 Interpretation and Evaluation

Interpretation and evaluation of discontinuities indication shall be performed during testing time which the surface under examined still maintained magnetic flux and detecting media. Mark the location of indication and evaluate those that are relevant in accordance with para 5.12 Acceptance Criteria. Only qualified Level II personnel are allowed to perform interpretation and evaluation of indication detected.

5.12 Acceptance Criteria

Limitation of imperfection shall be evaluated as in the following code and standard which is applicable in contract specification/ client’s acceptance criteria.

AWS D1.1 : Table 6.1 (Visual Inspection Acceptance Criteria.) 5.13 Qualification of Personnel

All NDT personnel performing the Magnetic Particle Testing shall be qualified and certified as Level II in accordance to ASNT-TC-1A (2006 Ed). The NDT Personnel shall be able to read Jagaer 1 or equivalent Chart at a distance not less than 1 foot. This requirement should be check on annual basis.

5.14 Reports

5.14.1 All test reports shall be prepared and completed by the tester. All reports shall be counter signed by client.

5.14.2 Reports shall be accompanied with sketches of the part being tested and location of indication, if any.

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6.0 SPECIAL REQUIREMENT

Nil

7.0 RECORDS

7.1 All MT shall be reported in a standard format (Attachment 1) accompanied by sketch of the part being tested and location of indication. This report shall be clearly written the defects if any.

7.2 The KHL Magnetic Particles Inspection Report shall contain, as a minimum, the information as shown in Attachment 1 Example of Magnetic Particle Inspection Report.

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Gouged Weld

A A’

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6.1.1 Remove slag, weld spatters and other debris from gouged area

6.12 Place the Magnetic Yoke across the weld with poles spacing approximately 6”. 6.13 Apply dry powder onto the magnetize surface with plastic powder container or blower so that the powder reach the surface as fluffy dust. Remove excess powder by blowing.

6.14 Visually inspect for magnetic indication. Steps (6.1.3) and (6.1.4) above to be carried out while the magnetizing current is ‘ON’.

6.15 Reposition the magnetic Yoke so that the magnetic filed is perpendicular to that of step (6.1.4) above, i.e at A-A and A’-A’.

6.16 If indication is observed, determined whether the indication is caused by discontinuity or false/irrelevant indication. This can be done by removing the indication by light grinding, visually examine the surface and re-MT.

6.17 If indication still appears after grinding, an approved repair procedure shall be followed

6.18 Inspection shall be carried out with sufficient lighting.

6.19 During a subsequent magnetization an overlap of at least one inch over the previous step is necessary to ensure complete coverage

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Page 21 of 21 Attachment I : Magnetic Particle Inspection Report

KENCANA HL SDN BHD

PROCEDURE NO. APPENDIX I

MAGNETIC PARTICLE INSPECTION REPORT Report No.: _{Page No.: 1 of 1}

Client : Project : Description : Inspection Date : Location : Specification : Acceptance Criteria: Material : Welding Process : Weld Prep. : Thickness : Surface Condition : Weld Type :

Test Technique : AC Yoke Type

White Contrast Paint: Black Magnetic Ink :

Equipment (S/No.) : Magnetizing Current: Yoke Type : Test Method : Lifting Power : Field Intensity : Indicator Result No. Joint Reference Interpretation

ACC REJ Remark

Date : ASNT LEVEL II __________________________ NDT Inspector Date : Reviewed By: ________________________ NDT Coordinator Date : Witnessed/Reviewed By: _____________________________ EMEPMI Authorized Representative